Wall panel with corner connector block

ABSTRACT

A wall panel includes hollow connector blocks in its lower corners, reinforced with anchor pins embedded in cementitious material of the panel. The connector blocks have holes for connecting adjacent wall panels together and for connecting the wall panels to the floor. Connectors are inserted via exposed apertures in the connector blocks that provide access to their hollow interiors. The apertures can be covered when the panels are fastened in place.

TECHNICAL FIELD

The present invention is related to a structural wall panel. Morespecifically, it relates to a wall panel with an embedded corner blockthat permits connection of the wall panel to the floor and to anadjacent similar wall panel.

BACKGROUND

The prefabrication of wall panels is a major improvement in theconstruction field. Wall panels are usually prepared and fabricatedoff-site. Typically, industry-standard pre-cast or tilt-up wall panelsdo not require high dimensional tolerances for assembly into a wall.

One type of wall panel may be a structural insulated panel (SIP), whichis usually made of several components, among them a central insulationcore or block core made of expanded polystyrene foam (EPS), extrudedpolystyrene foam, polyisocyanurate foam, polyurethane foam or compositehoneycomb and two layers of structural skin or structural board that canbe made of sheet metal, plywood, cement, magnesium oxide board ororiented strand board.

Fabricating the wall panels in a factory instead of on-site minimizesthe cost of their production. In the meantime, quality control of eachwall panel is improved because the influence of external parameters,such as the construction site, the weather and the construction workers,is minimized.

This background is not intended, nor should be construed, to constituteprior art against the present invention.

SUMMARY OF INVENTION

The present invention is related to a wall panel that has features forconnecting it to adjacent wall panels and the floor, in order toconstruct a modular wall. The wall panel has corner connectors placed ateach corner, integrated in the panel. The corner connectors also act asa point of fixation where a hook can be mounted in order to lift thewall panel. The corner connectors may also facilitate the alignment ofthe wall panels in the wall. Depending on the embodiment, the wallpanels disclosed herein provide at least one of the advantages describedin relation thereto.

Disclosed herein is a wall panel defined, when oriented as a section ofa wall, by a proximal face and a distal face that are connected to twoside edges, a top edge and a bottom edge, the wall panel comprising: avolume of cementitious material proximal to one of the side edges; avolume of cementitious material proximal to the bottom edge; a hollowconnector block in a corner defined by said one of the side edges, thebottom edge and the proximal face, wherein walls of the connector blockat said one of the side edges and bottom edge each define a hole, and anopen face of the connector block defines an aperture in the proximalface of the wall panel; and two anchor pins each connected to andprojecting from another different wall of the connector block into adifferent one of the volumes of cementitious material.

Also disclosed is a method of erecting a wall comprising providing twowall panels, each defined, when oriented as a section of a wall, by aproximal face and a distal face that are connected to two side edges, atop edge and a bottom edge, each wall panel comprising a volume ofcementitious material proximal to one of the side edges; a volume ofcementitious material proximal to the bottom edge; a hollow connectorblock in a corner defined by said one of the side edges, the bottom edgeand the proximal face, wherein walls of the connector block at said oneof the side edges and the bottom edge define a side hole and a bottomhole respectively, and an open face of the connector block defines anaperture in the proximal face; and two anchor pins each connected to andprojecting from another different wall of the connector block into adifferent one of said volumes of cementitious material; wherein, in oneof the wall panels said one of the side edges is a right edge and in theother of the wall panels said one of the side edges is a left edge. Themethod comprises: attaching a first of the wall panels to a floor usinga connector that passes through the bottom hole in the first wall panel;placing the second wall panel on the floor so that the side edges withthe connector blocks face each other and a second connector can bepassed through the side holes; tightening the second connector to drawthe second wall panel to the first wall panel; and attaching the secondwall panel to the floor using a third connector that passes through thebottom hole in the second wall panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate embodiments of the invention, whichshould not be construed as restricting the scope of the invention in anyway.

FIG. 1 is an exploded isometric view of a connector block, according toan embodiment of the present invention.

FIG. 2 is a side view of a connector block, according to an embodimentof the present invention.

FIG. 3 is a bottom view of a connector block, according to an embodimentof the present invention.

FIG. 4 is a side view of two adjacent wall panels prior to theirconnection, according to an embodiment of the present invention.

FIG. 5 is a close-up view of the area A of FIG. 4.

FIG. 6 is an isometric view of a wall panel, according to an embodimentof the present invention.

FIG. 7 is an isometric view of two wall panels to be connected,according to an embodiment of the present invention.

FIG. 8 is a broken side view of two connected wall panels, according toan embodiment of the present invention.

FIG. 9 is an exploded isometric view of a connector block with a cover,according to an embodiment of the present invention.

FIG. 10 is an exploded isometric view of two connector blocks, a sealportion and a connector, according to an embodiment of the presentinvention.

FIG. 11 is a flowchart for erecting a modular wall using wall panels,according to an embodiment of the present invention.

DESCRIPTION A. Exemplary Apparatus

Referring to FIG. 1, there is shown a connector block 10, made from alength of rounded-corner hollow section steel (HSS) such that itsoverall shape approximates a cube. In an upper wall 12 of the connectorblock 10 there is a threaded hole 14 that matches the thread 16 onanchor pin 18. The anchor pin 18 is, for example, a hex bolt, with shank20 and hexagonal head 21. In a right side wall 22 of the connector block10 there is a threaded hole 24 that matches the thread 26 on anchor pin28. The anchor pin 28 is, for example, a hex bolt, with shank 30 andhexagonal head 31.

In use, the anchor pins 18, 28 are screwed into the connector block 10,and the assembly is cast in place in cementitious material used in thefabrication of a wall panel

The front, or proximal face 32 of the connector block 10 is open,defining an aperture 34 that is exposed when the connector block is inplace in the wall panel, providing access to the hollow interior of theHSS. The hollow interior of the connector block 10 extends to the rear,or distal face 35 of the connector block.

A hole 36 in the bottom wall 38 of the connector block 10 allows aconnector (e.g. bolt) to be used to connect the wall panel, in which theconnector block is embedded, to a floor. To do this, the connector isinserted through the aperture 34 and into the hole 36, to be screwedinto a socket in the floor. There is generous clearance between theconnector and the hole 36 so that small adjustments to the position ofthe wall panel may be made before the connector is tightened to fastenthe wall panel to the floor. For example, the hole 36 is 19 mm (¾″) wideslotted hole, and the diameter of the shank of the connector that goesthrough the hole is 16 mm (⅝″).

A hole 46 in the left wall 48 of the connector block 10 allows anotherconnector (e.g. nut and bolt) to be used to connect the wall panel inwhich the connector block is embedded to an adjacent wall panel with asimilar connector block. To do this, one part of the connector (e.g.bolt) is inserted through one of the apertures 34 and into the hole 46,and another part of the connector (e.g. nut) is inserted through theother aperture 34 and onto the first part of the connector. Theconnector may by other than a nut and bolt in other embodiments. Thereis generous clearance between the connector and the hole 46 so thatsmall adjustments to the position of the second wall panel may be madebefore the connector is tightened to fasten the two wall panelstogether. For example, the diameter of the hole 46 is 19 mm (¾″) and thediameter of the shank of the connector that goes through the hole is 16mm (⅝″).

FIG. 2 is a side view of the connector block assembly 49, showingproximal face 32 and aperture 34 of the connector block 10. The extentto which the anchor pins 18, 28 are screwed into the threaded holes 14,24 respectively is shown to be only just through the walls of theconnector block. This so as not to restrict the inner volume of theconnector block, which would make it more difficult to insert theconnectors.

Optionally, the anchor pins 18, 28 are welded to the connector block 10.Note that in other embodiments, the holes 14, 24 may not be threaded andthe anchor pins 18, 28 may have a different physical format. Forexample, the anchor pins may be Nelson™ studs. In other embodiments, theanchor pins are lengths of threaded bar, or lengths of rebar. In someembodiments, the anchor pins extend more than half way along the side ofthe panel in which they are embedded. In other embodiments the anchorpins extend as far as practicable along the full length of the panel. Insome embodiments, the anchor pins extend from one connector block,embedded along the side of the panel to another connector block in thewall panel. The main function of the anchor pins 18, 28 is to provide amechanical anchor when they are embedded in a cured, cementitiousmaterial, and as such, the anchor pins may adopt any physical shape,size and/or surface profile that achieve this function.

FIG. 3 is a bottom view of the connector block 10, showing a bottom viewof the anchor pin 28. The underside of the end of the anchor pin 18,located in hole 14, is visible through slotted hole 36 in the bottomwall 38 of the connector block 10.

Note that while the anchor pins 18, 28 have been shown attachedcentrally to the solid faces 12, 22 of the connector block 10, it ispossible in other embodiments to attach the anchor pins off-center.

FIG. 4 is a side view of two adjacent wall panels 50, 60 located in aposition with respect to one another that they would be in prior totheir connection to form a modular wall. Proximal faces 51, 61 of thewall panels 50, 60 are visible to the observer. Wall panel 50 has a leftside edge 52, a bottom edge 53, a right side edge 54 and a top edge 55.Wall panel 60 has a left side edge 62, a bottom edge 63, a right sideedge 64 and a top edge 65. The distal faces of the wall panels 50, 60are not visible.

Wall panel 50 has a connector block 56 in its lower, right corner area58 defined by right side edge 54, bottom edge 53 and proximal face 51.Wall panel 60 has connector block 66 in its lower, left corner area 68defined by left side edge 62, bottom edge 63 and proximal face 61.Connector blocks 56, 66 are identical or similar to connector block 10,except that they are oriented as mirror images to each other in the wallpanels 50, 60.

Depending on the embodiment, wall panel 50 may have further cornerconnector blocks 71, 72, 73 and wall panel 60 may have further cornerconnector blocks 81, 82, 83. Connector block 71 may be identical toconnector block 66, and connector block 81 may be identical to connectorblock 56.

Furthermore, the wall panels 50, 60 may have side connector blocks 74-77and 84-87 respectively, which may be used to provide additionalconnection points between adjacent wall panels or between a wall paneland the floor or ceiling.

Connector block 56 and connector block 66 are connected together whenthe wall panels 50, 60 are joined. Optionally, an interveningcompressible seal, e.g. made of foam, is positioned between the wallpanels 50, 60 before they are fully connected to each other. The sealmakes the wall joint water and airtight.

If threaded bar is used as the anchor pins, connector block 56 is, insome embodiments, connected to side connector block 77 and sideconnector block 74 with the threaded bar. Likewise, in theseembodiments, the connector blocks at the other corners are connected totheir neighboring side connector blocks.

FIG. 5 is a close-up of area A in FIG. 4, encompassing the corner area58 of wall panel 50 and corner area 68 of wall panel 60. Connector blockassembly 90 is shown with its connector block 56 and anchor pins 91, 93.Anchor pin 91 is embedded in a volume of cementitious material 92proximal to the right side edge 54 of the wall panel 50. Anchor pin 93is embedded in a volume of cementitious material 94 proximal to thebottom edge 53 of the wall panel 50. The two volumes of cementitiousmaterial 92, 94 are contiguous, and contact the top wall and left wallrespectively of the connector block 56.

Connector block assembly 95 is shown with its connector block 66 andanchor pins 96, 98. Anchor pin 96 is embedded in a volume ofcementitious material 97 proximal to the left side edge 62 of the wallpanel 60. Anchor pin 98 is embedded in a volume of cementitious material99 proximal to the bottom edge 63 of the wall panel 60. The two volumesof cementitious material 97, 99 are contiguous, and contact the top walland right wall respectively of the connector block 66.

Connector block 56 defines an aperture 100 in its proximal face, whichis exposed and therefore also an aperture in the proximal face 51 ofwall panel 50. Connector block 66 defines an aperture 102 in itsproximal face, which is exposed, and therefore also an aperture in theproximal face 61 of wall panel 60. The distal faces of the connectorblocks 56, 66 are inside or embedded in the volume of the wall panels50, 60 respectively.

FIG. 6 is a view of wall panel 50, which has an overall rectangularcuboid shape or envelope. The connector block 56 is underflush with theproximal face 51 of the wall panel, as are all the other connectorblocks. This is so that, after the wall panel 50 has been installed inits final position and the various connectors have been tightened, theaperture that the connector block 56 defines can be filled or covered tothe same level as the proximal face 51 of the wall panel in preparationfor finishing, such as painting. The connector block 56 extends fromunderflush with the proximal face 51 of the wall panel 50 part of theway to the distal face 110 of the wall panel. This wall panel 50 is anexample of an SIP in which the structural strength is provided largelyby a reinforced cementitious frame within the inner, proximal half ofthe wall panel. The wall panel 50 has, for example, an insulating coreof EPS. As an example only, the wall panel 50 may measure 2.4 m×2.4m×0.2 m (8′×8′×8″).

The dimensions of the connector blocks (e.g. 56) and the positions andorientations of the connector blocks in the wall panel 50 should bedefined with a tight enough tolerance for the wall panel to be placedand fastened with sufficient accuracy in its intended location. Forexample, during fabrication of the wall panel 50, and particularlyduring casting of the cementitious material, the connector blocks (e.g.56) are screwed to the forms used for casting the wall panel, the formsholding the connector blocks in place during the casting.

FIG. 7 shows the two wall panels 50, 60 aligned ready to be connected toeach other. Assume to start with that wall panel 50 has been fastened inplace on the floor. Wall panel 60, with its left side edge 62 facing theright side edge 54 of wall panel 50, is then positioned so that the holein the bottom wall of the connector block 66 is close to or over asocket in the floor, or passes over an anchor stud in the floor. Aconnector is then used to connect the wall panels 50, 60 together viahole 120 in connector block 56 in the wall panel 50 and a similar holein the left wall of the connector block 66 in wall panel 60. As theconnector is tightened, wall panel 60 is drawn closer to wall panel 50.When tightened, wall panel 60 is then fastened to the floor using a boltscrewed into the in-floor socket, or by a nut, for example, tightenedonto an anchor stud projecting from the floor into connector block 66.

FIG. 8 is a side view of the two connected wall panels 50, 60, with seal125 between them. Wall panel 50 is connected to the floor (not shown) bya bolt 132, which is fastened into a threaded socket 133 in the floor,for example. The bolt 132 is placed through the aperture 134 of theconnector block 56 and screwed into the socket 133.

A bolt 140 is passed into the aperture 134 of the connector block 56,through a hole in the right side wall of the connector block 56, a holein the seal 125, and a hole in the left side wall of the connector block66. A nut 142 is placed through the aperture 138 in the connector block66 and onto the thread of the bolt 140, and it is then tightened tobring the wall panels 50, 60 together.

In some embodiments, a length of threaded bar with two nuts is used asthe connector that connects the two connector blocks 56, 66, instead ofnut 142 and bolt 140.

Wall panel 60 is connected to the floor by a bolt 136 screwed into athreaded socket 137. The bolt 136 is placed through the aperture 138 ofthe connector block 66 and screwed into the socket 137.

FIG. 9 is a connector block 150 in which the upper region 152 of thewalls, adjacent the proximal face, has been thinned to form a ledge 154a short distance below the proximal face of the connector block. A coveror plate 156 is dimensioned to fit within the thinned portion of thewalls of the connector block and sit on the ledge 154. The fit may be,for example, a push fit or a snap fit, or the cover may be glued intothe connector block 150. The cover 156 is put into the connector block150 after the wall panel in which it is embedded is fastened into place,to close the aperture. Finishing materials are then applied to the coverto make the proximal face of the wall panel uniform. The distal openface of the connector block 150 does not need a cover as it is insidethe volume of the wall panel, and therefore hidden when the cover 156 isin place.

FIG. 10 shows connector block 150 and a similar connector block 160,with intervening portion of seal 162. The connector blocks 150, 160 areconnected together with nut 164 and bolt 166, which passes through holes168, 169 and another hole (not visible) in the left wall of connectorblock 160.

B. Exemplary Method

FIG. 11 shows a method for erecting a modular wall using wall panels. Instep 170, a first wall panel 50 is provided and placed upright inposition in the wall. The position is such that the hole in the bottomwall of the connector block in the wall panel passes over acorrespondingly threaded socket embedded in the floor.

In step 172, the first wall panel 50 is fastened to the floor, byplacing a bolt through the aperture in the connector block, through theslotted hole in the bottom wall of the connector block and into thesocket, and then screwing the bolt into the socket.

In step 174, a second wall panel 60 is provided and placed upright closeto the first wall panel. The position is such that the hole in thebottom wall of the connector block in the wall panel 60 is approximatelyover another threaded socket embedded in the floor. The second wallpanel may be up to 2.5 cm (1″) away from the first panel, for example.

In step 178, the two wall panels are connected with a connector, such asa nut and bolt, through the holes in the exposed side walls of theconnector blocks. The nut and bolt are below flush with the proximalfaces of the wall panels through which the holes in the side walls ofthe connector blocks are accessed. In step 180, the nut and bolt aretightened to bring the second wall panel closer to the first wall paneland fasten the two panels together.

In step 182, the second wall panel is then fastened to the floor in thesame way that the first panel was fastened to the floor.

C. Variations

The reference to, for example, the side edges as left and right and thesurfaces as proximal or distal is non-limiting and simply for convenientreference, as the wall panel can be oriented in a variety of waysdepending on how it is used in the construction of a building.

It is worth noting that the actual rectangular shape, the proportionsand the dimensions shown are simply an embodiment of the presentinvention and can be subjected to modification.

The connector blocks may be positioned or oriented differently thanshown is the exemplary embodiments.

The edges of the wall panel may be covered with a protective or sealantlayer, for example. As such the cementitious material in someembodiments is proximal to the edges of the wall panel without extendingto the outer surface of the edge.

The connector blocks may also be used in stem walls (grade beams), floorpanels and roof panels.

In wall panels that are set on a base plate or anchoring pile there is anut welded inside the connector block with a bolt that is use to raiseor lower that corner of the wall panel.

Connector blocks embedded in the floor may be used to connect the wallpanels to the floor.

In general, unless otherwise indicated, singular elements may be in theplural and vice versa with no loss of generality.

Throughout the description, specific details have been set forth inorder to provide a more thorough understanding of the invention.However, the invention may be practiced without these particulars. Inother instances, well known elements have not been shown or described indetail and repetitions of steps and features have been omitted to avoidunnecessarily obscuring the invention. Accordingly, the specification isto be regarded in an illustrative, rather than a restrictive, sense.

It will be clear to one having skill in the art that further variationsto the specific details disclosed herein can be made, resulting in otherembodiments that are within the scope of the invention disclosed. Stepsin the flowchart may be performed in a different order, other steps maybe added, or one or more may be removed without altering the mainfunction of the invention. All parameters, dimensions, materials, andconfigurations described herein are examples only and actual ones ofsuch depend on the specific embodiment. Accordingly, the scope of theinvention is to be construed in accordance with the substance defined bythe following claims.

1. A wall panel defined, when oriented as a section of a wall, by aproximal face and a distal face that are connected to two side edges, atop edge and a bottom edge, the wall panel comprising: a volume ofcementitious material proximal to one of the side edges; a volume ofcementitious material proximal to the bottom edge; a hollow connectorblock in a corner defined by said one of the side edges, the bottom edgeand the proximal face, wherein walls of the connector block at said oneof the side edges and the bottom edge each define a hole, and an openface of the connector block defines an aperture in the proximal face ofthe wall panel; and two anchor pins each connected to and projectingfrom another different wall of the connector block into a different oneof the volumes of cementitious material.
 2. The wall panel of claim 1,wherein each anchor pin has a head with a diameter that is larger than adiameter of a shank of the anchor pin, each head being distal from theconnector block.
 3. The wall panel of claim 1, wherein the anchor pinsare hex bolts that are screwed into further, threaded holes in theconnector block.
 4. The wall panel of claim 1, wherein the anchor pinsare threaded bars that are screwed into further, threaded holes in theconnector block.
 5. The wall panel of claim 1, wherein the anchor pinsare welded to the connector block.
 6. The wall panel of claim 1, whereina further open face of the connector block is inside the wall panel. 7.The wall panel of claim 1, wherein the connector block is a length ofhollow structural steel with a rounded-corner square cross-section. 8.The wall panel of claim 7, wherein the length of the hollow structuralsteel is equal to a side of the square cross-section.
 9. The wall panelof claim 1, wherein the connector block and anchor pins are cast inplace in the volumes of cementitious material.
 10. The wall panel ofclaim 1, wherein the volumes of cementitious material are contiguous.11. The wall panel of claim 1, wherein the hole in the wall of theconnector block at the bottom edge is slotted.
 12. The wall panel ofclaim 1, wherein the connector block comprises a ledge on an interiorwall of the connector block.
 13. The wall panel of claim 12, comprisinga plate that is dimensioned to sit on the ledge and fill the aperture.14. The wall panel of claim 1, comprising: another volume ofcementitious material proximal to the other side edge; another hollowconnector block in a corner defined by the other side edge, the bottomedge and the proximal face, wherein walls of the other connector blockat the other side edge and the bottom edge each define another hole, andan open face of the other connector block defines another aperture inthe proximal face of the wall panel; and two further anchor pins eachconnected to and projecting from another different wall of the otherconnector block into a different one of the volumes of cementitiousmaterial proximal to the bottom edge and the other side edge.
 15. Amethod of erecting a wall comprising: providing two wall panels, eachdefined, when oriented as a section of a wall, by a proximal face and adistal face that are connected to two side edges, a top edge and abottom edge, each wall panel comprising: a volume of cementitiousmaterial proximal to one of the side edges; a volume of cementitiousmaterial proximal to the bottom edge; a hollow connector block in acorner defined by said one of the side edges, the bottom edge and theproximal face, wherein walls of the connector block at said one of theside edges and the bottom edge define a side hole and a bottom holerespectively, and an open face of the connector block defines anaperture in the proximal face; and two anchor pins each connected to andprojecting from another different wall of the connector block into adifferent one of said volumes of cementitious material; wherein, in oneof the wall panels said one of the side edges is a right edge and in theother of the wall panels said one of the side edges is a left edge;attaching a first of the wall panels to a floor using a connector thatpasses through the bottom hole in the first wall panel; placing thesecond wall panel on the floor so that the side edges with the connectorblocks face each other and a second connector can be passed through theside holes; tightening the second connector to draw the second wallpanel to the first wall panel; and attaching the second wall panel tothe floor using a third connector that passes through the bottom hole inthe second wall panel.
 16. The method of claim 15 comprising: placing aseal between the wall panels before tightening the second connector. 17.The method of claim 15 comprising: covering the apertures in theconnector blocks with plates.